Filtronic has validated plastic packaging for high‑power gallium nitride (GaN) radio‑frequency devices with support from UK Defence Innovation’s Defence Technology Exploitation Programme (DTEP). According to a UK Government case study, the project began in 2022 and, by August 2025, delivered a Quad Flat No‑lead (QFN) solution that meets performance requirements while reducing size and mass for defence applications.
GaN devices underpin modern radar, electronic warfare and secure communications by delivering higher efficiency and power density than silicon. Historically they have been packaged in ceramic housings that increase weight and volume. Filtronic’s plastic QFN approach is designed for strict Size, Weight and Power targets across air, maritime, land and space platforms, with attention to improved thermal handling.
The government case study records that Filtronic designed, built and tested more than 150 units over two years, subjecting them to high‑moisture exposure, thermal cycling and electrical stress. All devices passed electrical performance tests, providing confidence to move from engineering validation towards scaled manufacture.
DTEP backing paired Filtronic with a major UK defence prime to shape requirements and accelerate adoption. Filtronic reports that this partnership informed technical choices and helped secure board approval for investment in a dedicated plastic‑packaging line and moulding capability in the UK.
Practically, the new packaging enables denser RF assemblies by fitting more devices in the same footprint. The government case study states that systems can achieve greater power, improved thermal efficiency and lighter payloads when compared with traditional ceramic packages, benefits that are material for radar arrays and other high‑power modules.
The case study highlights commercial outcomes since project launch: Filtronic has doubled its workforce, tripled revenue and opened a new manufacturing facility in North East England in 2025. The company has also secured follow‑on funding from UK Research and Innovation to investigate enhanced thermal management techniques and reports strong interest from defence and space customers.
Filtronic positions the programme as strengthening sovereign capability, noting that most design and manufacturing activities are conducted domestically. This aligns with UKDI’s stated aim to reinforce home‑based supply chains for strategic technologies while progressing innovations from concept to production.
The company originated as a University of Leeds spin‑out more than 45 years ago and now focuses on RF and mmWave solutions for defence, space and 5G markets. The case study also points to commercial traction beyond defence primes, referencing supply of components used within SpaceX’s Starlink programme.
For procurement teams, the outcome provides a UK option to replace ceramic packages without a reported performance penalty, subject to platform‑level qualification. Programmes with stringent SWaP objectives can consider plastic‑packaged GaN parts where environmental and reliability requirements are demonstrated during acceptance.
The government case study credits UKDI Innovation Partners with hands‑on guidance through application and delivery. For policymakers, the project illustrates how targeted co‑funding tied to prime‑SME collaboration can remove specific engineering barriers and add UK manufacturing capacity in a critical technology area.